Twisting then cabling BCF yarns to impart torque

ABSTRACT

A method for forming a highly textured loop pile rug and/or carpet using the torque created by twisting then cabling bulk continuous yarns. A flooring article having a textured effect by creating torque in the yarn through the twisting and cabling of bulk continuous fiber.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to ProvisionalApplication 60/280,586 filed on Mar. 30, 2001.

FIELD OF THE INVENTION

[0002] The invention relates to twisting bulk continuous fiber orsynthetic yarn to create torque in the yarn to give a highly texturedeffect to rugs and carpets created from the yarn.

BACKGROUND OF THE INVENTION

[0003] The following disclosures may be relevant to various aspects ofthe present invention and may be briefly summarized as follows:

[0004] U.S. Pat. No. 3,950,932 to Durling discloses a multicolored,cabled, stuffer box crimped yarn containing filaments of respectively atleast two noncontrasting colors and a contrasting color, the filamentsof the at least two non-contrasting colors imparting a heatherappearance to the yarn and the filaments of the contrasting colorimparting color accents to the yarn, is produced by cabling together atleast three stuffer box crimped multifilament ends, each of the threeends containing filaments of at least two non-contrasting colors and oneof the three ends containing filaments of the contrasting color in adiscrete grouping and in a proportion greater than the proportion in thesame end of filaments of any individual non-contrasting color and, priorto being twisted together with the other ends, containing a twist in thesame sense as the twist to be imparted in the step of twisting togetherall the ends and, after being twisted together with the other ends,preferably containing a twist of a higher degree than the twistcontained in the other ends.

[0005] U.S. Pat. No. 4,206,589 to Markey et al. discloses a method offorming a self-twisted fibrous creating a textured effect in the finalyarn; and tufting the final yarn in a loop pile construction of aflooring article having the textured effect.

[0006] Pursuant to another aspect of the present invention, there isprovided a method for forming a textured loop style flooring articlecomprising: twisting at least one feed yarn end with a second feed yarnend using a first twist forming a third yarn end; twisting a fourth feedyarn end with a fifth feed yarn end using the first twist forming asixth yarn end; cabling the third yarn end and the sixth yarn endtogether in a same direction as the twisting of the yarn ends in formingthe third yarn end and the sixth yarn end using a cable twist forming afinal yarn, wherein a differential twist occurs between the first twistand the cable twist imparting a torque to the final yarn creating atextured effect in the final yarn; and tufting the final yarn in a looppile construction of a flooring article having the textured effect.

[0007] Pursuant to another aspect of the present invention, there isprovided a flooring article having a textured effect comprising: atleast two first yarn ends twisted together with a first twist forming athird yarn end, said third yard end and another at least two-ply yarnend twisted together with a cable twist in the same direction as thefirst twist creating a final yarn; a differential twist occurringbetween the first twist and the cable twist imparts a torque to saidfinal yarn for a textured effect; and said final yarn being tufted intoa loop pile construction.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention will be more fully understood from the followingdetailed description, taken in connection with the accompanying drawing,in which:

[0009]FIG. 1 is a schematic illustration of the process described inExample 1.

[0010]FIG. 2 is a schematic illustration of the process described inExample 2.

[0011]FIG. 3 is a photographic illustration of a textured effect.

DETAILED DESCRIPTION OF THE INVENTION

[0012] Definitions

[0013] The following definitions are provided as reference forinterpretation of these terms used in the context of this specificationand the accompanying claims.

[0014] 1. Cable: to twist together two or more folded yarns.

[0015] 2. Cabled yarn: is two or more folded yarns twisted together inone or more operations. Combinations of single yarn(s) may be describedas cabled yarns, e.g. a single yarn twisted together with two foldedyarns to build yarn size and impart texture to the resulting yarn.

[0016] 3. Conventional Twister: A system of producing a folded yarn bytwisting together two or more single yarns simultaneously.

[0017] 4. Dpf: denier per filament.

[0018] 5. End: An individual strand or filament for twisting.

[0019] 6. Folded yarn or Plied yarn: A yarn in which two or more singleyarns are twisted together in one operation, e.g., two-folded yarn,three-fold yarn, etc. (In some sections of the textile industry theseyarns are sometimes referred to as two-ply three-ply, etc.)

[0020] 7. Loop pile: The pile of a carpet consisting of loops. (e.g.uncut pile)

[0021] 8. Pile: a surface effect on a fabric formed by tufts or loops ofyarn that stand up from the body of the fabric. In carpet, pile is thepart of the carpet consisting of textile yarns or fibers, cut or looped,projecting from the substrate and acting as the use-surface.

[0022] 9. Textured pile: A pile in which the surface character is variede.g., by having areas of different characteristics or by combinations ofdifferent yarn or pile types, (e.g., soft and hard twist.)

[0023] 10. Tpi: turns per inch (e.g. tpi defines a degree of twist whichis the number of turns or twist per unit length)

[0024] 11. Twist direction: is described as

or

according to which of these letters has its center inclined in the samedirection as the surface elements of a given twisted yarn, when the yarnis viewed vertically (e.g. twisting in the direction is clockwise andthe z-direction is counter-clockwise).

[0025] In the present invention, BCF (bulk continuous fiber) orsynthetic yarn such as nylon or other polyamides are used to create atextured loop pile construction for rugs/carpets. Unlike cotton, whichhas a tendency to mat and pill, is difficult to clean, and is difficultto dye dark colors, synthetic fiber such as nylon 6, 6 is durable, haseasy care, colorfast, quick drying and resistant to fuzzing/pilling.Using a conventional twister (such as Volkman, Verdol, ICBT & Hammel),the feed fiber or yarn is plied or twisted with another (i.e. a second)fiber or yarn of the same or different deniers forming a third yarn.This initial twisting (i.e. or first twist) of the yarn to form a thirdyarn as indicated above is preferably about 1.0 to about 10.0 twists perinch. The feed yarn is preferably at least two-ply and, most preferablytwo-plied or three-plied. The feed yarns can be colored or whitedyeable.

[0026] Then, at least two of the plied or twisted third yarns are thencabled together forming a final yarn. The third yarns cabled togethercan be either of the same denier, or of different deniers. (For example,a first third yarn can be comprised of two 2250 denier/11.5 dpf and asecond third yarn can be comprised of two 1400 denier/10 dpf. Then thefirst third yarn and second third yarn of different deniers can be cabletwisted forming a final yarn. The dpf effects the hand or softness ofthe finished yarn.) The total denier of the final yarn preferably rangesfrom about 2,000 to about 20,000. The yarns that are cabled togetherpreferably have a cable twist of about 0.5 to about 10 twists per inch.

[0027] In the present invention, a twist differential must occur betweenthe initial twisting of the feed yarn and the cable twisting to providea torque to the final yarn for the textured look desired. The torquecausing the textured effect is a novel element of the present invention.The twist differential is a delta between the degree of twist at theinitial twist and the cable twist. (For example, if the initial twist is3.0 tpi and the cable twist is 2.0 then the twist differential is (3.0tpi

2.0 tpi) 1.0 tpi.). Furthermore, the twisting and the cable twistingmust be twisted in the same direction (e.g. s-direction or thez-direction). That is, if the initial twist is in the s-direction thenthe cable twist for the final yarn must be in the s-direction not thez-direction. Similarly if the initial twist is in the z-direction thenthe cable twist for the final yarn must also be in the z-direction. Inorder to maximize the torque/textured effect, the yarn should not beheatset.

[0028] There can be additional twisting of the yarns with the same ordifferent deniers after the initial twisting and prior to cabling intothe final yarn.

[0029] Referring now to the drawings, where the showing is for thepurpose of describing an embodiment of the invention and not forlimiting same. The twisting operations may be conducted on anyconventional twisters such as Volkman, Verdol, ICBT & Hammel. Theexamples below were twisted using a Volkman twister.

[0030] Examples of the present invention are illustrated in FIGS. 1 and2 and will be briefly described below. The feed yarn, end-A in FIG. 1,is the starting point. A variety of samples of different denier weremade using the following yarns as end-A:

[0031] 1400-denier/10-dpf

[0032] 2250-denier/11.5 dpf

[0033] 995×2/12.5 dpf

[0034] 1800-denier/8-dpf

[0035] The same process as described in Example 1 below was used foreach of these samples which also yielded the textured loop pile of thepresent invention.

EXAMPLES Example 1

[0036] One end of 2200-denier/8-dpf (end-A in FIG. 1) was plied withanother end of 2200-denier/-8-dpf (end-A in FIG. 1) at 4.0 twist perinch in “s” direction to form a 4400-denier (end-B in FIG. 1). Then, twoends of 4400-denier (end-B in FIG. 1) are cabled together at 3.0 twistsper inch in the “s” direction to form a 8800-denier (end-C in FIG. 1).The differential twist (i.e. 4.0 twist per inch

3.0 twist per inch=1.0 twist per inch) of 1.0 twist per inch is impartedas torque to the final yarn. End-C in FIG. 1, was tufted into a rug orcarpet in a loop pile construction on a backing using a conventionaltufting machine to achieve a textured loop aesthetics. The yarn was notheatset in order to maximize the torque/textured effect.

Example 2

[0037] One end of 2200-denier/8-dpf (end-A in FIG. 2) was plied withanother end of 2200-denier/-8-dpf (end-A in FIG. 2) at 4.0 twists perinch in “s” direction to form a 4400-denier (end-B in FIG. 2). One endof 1400-denier/10-dpf (end-C in FIG. 2) was plied with another end of1400-denier/10-dpf (end-C in FIG. 2) at 4.0 twists per inch in the “s”direction to form a 2800-denier yarn (end-D in FIG. 2). Then one end-Bwas cabled with one end-D at 3.0 twist per inch in “s” direction to forma 7200-denier (end-E in FIG. 2). The differential twist of 1.0 twist perinch imparted the torque to the final yarn. Then the end-E, shown inFIG. 2, was tufted into a rug or carpet in a loop pile construction on abacking on a conventional tufting machine to give a textured loopaesthetics. To maximize the torque/textured effect, the yarn was notheatset.

[0038] Reference is now made to FIG. 3, which shows the textured effectof the yarn in a loop pile construction. The yarn, as shown, has beentwisted and cabled to impart the torque to the BCF or synthetic yarn andtufted.

[0039] It is therefore, apparent that there has been provided inaccordance with the present invention, twisting then cabling BCF yarnsto impart torque for a textured loop pile construction that fullysatisfies the aims and advantages hereinbefore set forth. While thisinvention has been described in conjunction with a specific embodimentthereof, it is evident that many alternatives, modifications, andvariations will be apparent to those skilled in the art. Accordingly, itis intended to embrace all such alternatives, modifications andvariations that fall within the spirit and broad scope of the appendedclaims.

It is claimed:
 1. A method for forming a textured loop style flooringarticle comprising: twisting a first yarn end with a second yarn endusing a first twist forming a third yarn end; cabling two third yarnends in a same direction as the first twist of the first yarn end andthe second yarn end using a cable twist forming a final yarn, wherein adifferential twist occurs between the first twist and the cable twistimparting a torque to the final yarn creating a textured effect in thefinal yarn; and tufting the final yarn in a loop pile construction of aflooring article having the textured effect.
 2. The method of claim 1,wherein the third yarn comprises a two-plied yarn and a three-pliedyarn.
 3. The method of claim 1 or 2, wherein the first twist ranges fromabout 1.0 twists per inch to about 10.0 twists per inch.
 4. The methodof claim 3, wherein the cable twist ranges from about 0.5 twists perinch to about 10 twists per inch.
 5. The method of claim 1 or 4, whereinthe differential twist ranges from about 0.5 twists per inch to about9.5 twists per inch.
 6. The method of claim 1, wherein the samedirection of the twist for the twisting step and the cabling step is inan s-direction.
 7. The method of claim 1, wherein the same direction ofthe twist for the twisting step and the cabling step is in az-direction.
 8. The method of claim 1, wherein the final yarn comprisesa denier of about 2000 to about 20,000.
 9. The method of claim 1,wherein the final yarn comprises a non heatset synthetic yarn.
 10. Amethod for forming a textured loop style flooring article comprising:twisting at least one feed yarn end with a second feed yarn end using afirst twist forming a third yarn end; twisting a fourth feed yarn endwith a fifth feed yarn end using the first twist forming a sixth yarnend; cabling the third yarn end and the sixth yarn end together in asame direction as the twisting of the yarn ends in forming the thirdyarn end and the sixth yarn end using a cable twist forming a finalyarn, wherein a differential twist occurs between the first twist andthe cable twist imparting a torque to the final yarn creating a texturedeffect in the final yarn; and tufting the final yarn in a loop pileconstruction of a flooring article having the textured effect.
 11. Themethod of claim 10, wherein the third yarn comprises a two-plied yarnand a three-plied yarn.
 12. The method of claim 10 or 11, wherein thefirst twist ranges from about 1.0 twists per inch to about 10.0 twistsper inch.
 13. The method of claim 11, wherein the cable twist rangesfrom about 0.5 twists per inch to about 10 twists per inch.
 14. Theflooring article of claim 10 or 13, wherein the differential twistranges from about 0.5 twists per inch to about 9.5 twists per inch. 15.The method of claim 10, wherein the same direction of the twist for thetwisting step and the cabling step is in an s-direction.
 16. The methodof claim 10, wherein the same direction of the twist for the twistingstep and the cabling step is in a z-direction.
 17. The method of claim10, wherein the final yarn comprises a denier of about 2,000 to about20,000.
 18. The method of claim 10, wherein the final yarn comprises anon heatset synthetic yarn.
 19. A flooring article having a texturedeffect comprising at least two first yarn ends twisted together with afirst twist forming a third yarn end, said third yard end and another atleast two-ply yarn end twisted together with a cable twist in the samedirection as the first twist creating a final yarn; a differential twistoccurring between the first twist and the cable twist imparts a torqueto said final yarn for a textured effect; and said final yarn beingtufted into a loop pile construction.
 20. A flooring article of claim19, wherein the another at least two-ply yarn end comprises a same ordifferent denier than said third yard end.
 21. The flooring article ofclaim 19 or 20, wherein the first twist comprises about 1.0 twists perinch to about 10 twists per inch.
 22. The flooring article of claim 21,wherein the cable twist ranges from about 0.5 twists per inch to about10 twists per inch.
 23. The flooring article of claim 19 or 22, whereinthe differential twist ranges from about 0.5 twists per inch to about9.5 twists per inch.
 24. The flooring article of claim 19, wherein thefirst twist and cable twist are in an s-direction.
 25. The flooringarticle of claim 19, wherein the first twist and the cable twist are ina z-direction.
 26. The flooring article of claim 19, wherein the finalyarn comprises a denier of about 2,000 to about 20,000.
 27. The flooringarticle of claim 19, wherein the final yarn comprises a non heatsetsynthetic yarn.